Flex circuit/balloon assemblies utilizing textured surfaces for enhanced bonding

Abstract

Systems, methods and devices for remodeling a tissue of or adjacent to a body passageway may include or utilize a catheter having an expandable balloon with a plurality of flexible circuits. In some instances, laser texturing may be utilized to facilitate enhanced bonding of the flexible circuits to the expandable balloon.

What is claimed is: 
     
         1 . A balloon assembly, comprising:
 a radially-expandable balloon comprising an outer textured surface;   a plurality of flexible circuits attached to the radially-expandable balloon;   wherein at least some of the flexible circuits include a textured balloon facing surface; and   one or more electrodes coupled to at least some of the plurality of flexible circuits.   
     
     
         2 . The balloon assembly of  claim 1 , wherein the outer textured surface of the radially-expandable balloon comprises a plurality of sub-micron nodules. 
     
     
         3 . The balloon assembly of  claim 2 , wherein the plurality of sub-micron nodules are randomly distributed throughout a textured area of the outer textured surface. 
     
     
         4 . The balloon assembly of  claim 2 , wherein the outer textured surface of the radially-expandable balloon comprises polyethylene terephthalate. 
     
     
         5 . The balloon assembly of  claim 1 , further comprising an adhesive attaching at least some of the flexible circuits to the radially-expandable balloon. 
     
     
         6 . The balloon assembly of  claim 1 , wherein the textured balloon facing surface comprises a plurality of sub-micron nodules. 
     
     
         7 . The balloon assembly of  claim 6 , wherein the textured balloon facing surface of the flexible circuits includes a polyimide. 
     
     
         8 . The balloon assembly of  claim 1 , wherein at least some of the plurality of flexible circuits extend longitudinally along the balloon and are circumferentially spaced about the balloon. 
     
     
         9 . The balloon assembly of  claim 8 , wherein at least some of the plurality of flexible circuits include a plurality of longitudinally and circumferentially spaced electrodes. 
     
     
         10 . The balloon assembly of  claim 1 , wherein at least some of the flexible circuits include openings extending therethrough, such openings configured to increase flexibility of the flexible circuits. 
     
     
         11 . The balloon assembly of  claim 1 , wherein at least some of the flexible circuits include rounded corners. 
     
     
         12 . The balloon assembly of  claim 1 , wherein at least some portions of some of the flexible circuits are shaped to at least approximately key to a shape of at least one adjacent flexible circuit. 
     
     
         13 . The balloon assembly of  claim 1 , wherein at least some of the flexible circuits include a heat sensing device positioned at least partially within a layer of the flexible circuit that includes the textured balloon facing surface. 
     
     
         14 . The balloon assembly of  claim 13 , wherein at least some of the flexible circuits include a conductive layer above the layer that includes the textured balloon facing surface, at least a portion of the conductive layer being electrically coupled to the heat sensing device. 
     
     
         15 . The balloon assembly of  claim 1 , wherein a maximum thickness of at least some of the flexible circuits is less than 0.2 mm. 
     
     
         16 . The balloon assembly of  claim 1 , wherein the one or more electrodes include a pair of bipolar electrodes. 
     
     
         17 . A balloon assembly, comprising:
 (a) a radially-expandable balloon comprising an outer textured surface defining a textured surface area comprising a plurality of randomly distributed sub-micron nodules; and   (b) a plurality of flexible circuits attached to the radially-expandable balloon, wherein at least some of the flexible circuits include a textured balloon facing surface.   
     
     
         18 . The balloon assembly of  claim 17 , wherein the radially-expandable balloon further comprises an area of the outer textured surface that is non-textured. 
     
     
         19 . The balloon assembly of  claim 17 , wherein at least some of the plurality of flexible circuits include a pair of bipolar electrodes. 
     
     
         20 . A method of making a balloon assembly, comprising:
 (a) texturing an outer surface of a radially-expandable balloon; and   (b) adhering a plurality of flexible circuits to the radially-expandable balloon, wherein at least some of the plurality of flexible circuits include a pair of bipolar electrodes.